Acoustic Liner Light-Reflecting Layer for Laser Drilling

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Solution Overview

Problem

The existing methods for forming holes in the face skin of acoustic liners for gas turbine engines are time-consuming and risk damaging other components, such as the back skin, during the laser hole formation process.

Innovation Solution

The acoustic liner design includes a light-reflecting layer, such as aluminum foil, which reflects laser energy and prevents damage to the back skin during hole formation, allowing for efficient attachment of the face skin to the core and subsequent laser drilling of holes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser is applied to form holes in the face skin, then hole formation speed is improved, but the back skin may be damaged by laser energy

Engineering Contradiction:

Improvehole formation speedVSAvoidlaser damage to back skin

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

A light-reflecting layer is introduced as an intermediary between the laser source and the back skin. This layer reflects the laser energy away from the back skin, preventing damage while allowing the laser to effectively form holes in the face skin. The light-reflecting layer acts as a protective mediator that manages the harmful laser energy.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The laser energy that would otherwise damage the back skin is converted into a beneficial protective mechanism through the light-reflecting layer. The reflected laser energy can be redirected or dissipated harmlessly, transforming a potential harm into a safe process that enables rapid hole formation without compromising the back skin.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Manufacturing precision

If reticulation of core and holes of face skin is performed, then attachment precision is improved, but manufacturing time increases considerably

Engineering Contradiction:

Improveattachment precisionVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The light-reflecting layer is applied to the back skin before the laser hole formation process. This preliminary action prepares the surface to reflect laser energy, preventing damage in advance and eliminating the need for time-consuming post-processing or protective measures during hole formation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The traditional mechanical reticulation process is replaced with a laser-based system. The laser rapidly forms holes through the face skin without requiring mechanical reticulation of the core, dramatically reducing manufacturing time while maintaining precision through the protective light-reflecting layer.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces the time required for hole formation and minimizes the risk of damage to the back skin, enhancing the manufacturing efficiency and reliability of acoustic liners.

Implementation Method 1

a light-reflecting layer, such as aluminum foil, which reflects laser energy and prevents damage to the back skin during hole formation

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

application of the laser to form the holes presents a risk of damage to other portions of the acoustic liner

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11719160B2Acoustic liner and method of forming same

Publication Date: 2023.08.08 ROHR INC

AI summary

An acoustic liner includes a core including a plurality of cells extending between a first side of the core and a second side of the core opposite the first side of the core. The acoustic liner further includes a back skin including a light-reflecting layer. The light-reflecting layer includes a first side attached to the first side of the core. The acoustic liner further includes a face skin. The face skin includes a first side attached to the second side of the core.